Part 2 of our series delves into the two most important words in today’s industry: pipeline integrity. Interviewed are executives and experts in the challenging business of inspection and repair.

Entegra LLC

Pipeline integrity is certainly the mantra of the midstream, a sector that is increasingly attracting entrepreneurs such as Mark Olson, a one-time race car driver and now president of his own firm, Indianapolis, Ind.-based Entegra LLC, which provides pipeline inspection services.

It may seem like a cliché, Olson acknowledges, but to the pipeline sector, “Necessity is the mother of invention.”

“I view the need for R&D as more of a pull, rather than a push. That being said, the nature of technology development is to continuously accelerate, and it makes sense that the pace of R&D must also increase to fuel that growth. As a service provider, it’s our duty to drive technology advancement on a proactive basis to provide solutions to our customers,” he said.

He also discussed an issue raised earlier by Heath Consultants’ Paul Wehnert.

“Honestly, regulations have a hard time keeping up with technology. For example, look at how the FAA is struggling to integrate drone technology into the Air Traffic Control system. So, while pipeline owners operate in a regulatory environment, the regulatory drivers are secondary.

“Most pipeline owners subscribe to the philosophy of ‘Operational Excellence’, which aspires to never spill one drop. Environmental stewardship, employee and public safety, and profitability are the rewards of excellent operations,” he says.

But on the flip side?

“Operators are required by regulation to maintain their pipeline assets against all threats. The cost of failure, in terms of public relations, regulatory intervention, and financial impact, is quite severe,” Olson said.

“The economics related to both reaping the rewards of excellent operations and avoiding the cost of failure is the primary driver behind technology advancements in the midstream pipeline sector.”

Olson explained how many advancements start out.

“It was really exciting to participate in a recent PHMSA R&D workshop. Industry subject matter experts (a fairly even mix of pipeline operator and service company representatives) were invited to join one of five breakout groups. Each brainstormed potential ideas (either new ideas or further advancement to ongoing R&D projects) for future funding. The top three most promising and/or most impactful ideas from each breakout group were then presented to PHMSA for R&D funding.”

While pipeline operators provide an equal or greater amount of R&D funding (compared to government funding), market forces continue to drive the majority of technology advancements. Service companies compete with one another to provide the technology solutions required by pipeline operators.

“Most advances are evolutionary rather than revolutionary. In many ways, the pipeline industry is a very mature industry. The Romans built pipelines, after all. So, the day-to-day blocking and tackling, combined with continuous improvement should always be a primary focus.

“For example, while already a mature technology in the early 2000s, I was proud to oversee the first commercialization of the collapsible, magnet bar-style MFL (magnetic flux leak) inline inspection (ILI) platform and the subsequent invention of the MFL/caliper combination ILI systems. And (at Entegra) to be able to further evolve MFL technology again by quadrupling the data resolution,” Olson said.

For he and others who have dedicated their livelihood to improve pipeline safety and efficiency, the work is more about a cause than just another job.

“What I love about the ILI business is that one can assess the current condition of a pipeline and identify potential threats before they actually become a concern. Outside of ILI, expect future products and technologies that are similarly proactive or preventative in nature. An example might include remote monitoring tools.

“From metal loss assessment methodologies, we’re hearing of a great need for better Probability of Identification (POI) performance from crack assessment ILI tools. Whereas the metal loss threat mechanism is well understood, it seems as if the industry is still learning about cracks as a threat. Expect exciting advancement in this field in the years to come.”

Still, looking forward needs a huge question mark, Olson suggested.

“Expect something disruptive, as well. It seems there is no way to predict which crazy idea will change the way we view our world. But, as they say, ‘the only constant is change.’ There’s a new approach to an old problem out there … and a lot of interesting and smart people pursuing it.”

T.D. Williamson

Inline inspection specialist, Tulsa, Okla.-based T.D. Williamson has a well-earned global reputation built over generations for servicing pipeline assets.

The competitive pigging sector, as it is generally known, has been at the forefront of technological change for several years already, but doesn’t that effort seem to be gaining even more strength?

“The short answer is yes,” said Chuck Harris, product line director, Integrated Pigging and Pipeline Integrity Solutions, TDW. “While petroleum products delivered by pipeline reach their destinations safely 99.999% of the time, the pipeline industry continues its pursuit of zero-safety incidents no harm to the public and environment. This objective will be achieved through safety and integrity management systems as well as technology advancement.”

 

Harris noted that emphasis on safety has resulted in updated regulations, including hazardous liquids and natural gas transmission regulations pending release to the Federal Register in early 2019.

He explained the process that ultimately leads to improved products and services.

It’s a process that takes plenty of time, research, funding, collaboration and commitment from all sides.

“The industry collaborates to identify and close safety and integrity gaps via PHMSA, PRCI (Pipeline Research Council International), API (American Petroleum Institute), INGAA (Interstate Natural Gas Association of America), and others. Through these forums, we identify the most critical objectives to enhance pipeline safety, potential to leverage existing technologies in new ways, and opportunities for further development.

“Furthermore,” Harris added, “updates to and creation of new guidance supports stated goals. Examples include: API RP 1173 – Pipeline Safety Management Systems, API 1176 - Assessment and Management of Cracking in Pipelines, and API 1160 – Managing System Integrity for Hazardous Liquids Pipelines which received significant updates in 2018.”

What proportion of new technology is sourced from government vs. industry?

“It is difficult to make this distinction globally,” Harris said. “For example, many regulated pipeline operators have conditional licenses that commit them to invest in new technology, which could be considered an industry- or government-driven source.

“Within the service sector, the mix of sponsored technology vs. self-funded programs varies across the spectrum – from boutique companies developing customer-specific applications to multinational players who focus on their own multi-generational technology.”

What’s in store from this active service-providing community?

“Improved detection of interacting threats, two or more adjacent anomalies that may interact to weaken the pipeline more than either would individually, will drive innovation,” Harris said.

“Over the next five years, one can expect further expansion of multiple dataset concepts, which can include multiple magnetic fields, field angles, geometry technology, mapping, etc. on the same inspection platform, as well as ultrasonic (UT), strain, advanced sensor technologies, and other means to enhance detection, identification, sizing, and prioritization of interacting threats.”

Listening to customers, Harris says the industry needs service providers to leverage existing technologies in new ways and/or develop complementary technologies to close detection gaps. Specific needs relate to improving detection and characterization of mechanical damage and cracking, girth weld assessments, and leveraging strain data.

ADV Integrity Inc.

For over a quarter century, Chris Alexander, Ph.D., PE, has become an acknowledged expert for the evaluation of numerous technologies such as composite materials in pipeline repair. His expertise also studies the effects of dents and mechanical damage on the structural integrity of onshore and offshore pipelines.

In this interview, Alexander, president of ADV Integrity Inc., a Houston-based company he recently founded, offers a cogent explanation of pipeline integrity.

“Operational risks are a major consideration for pipeline operators in terms of making decisions. Technology and its integration into major decisions associated with integrity management have become not only important, but essential. Although integrity management has many facets, from my perspective, three of the more important aspects include inspection, assessment, and rehabilitation.”

Nor does he overlook the advances made with inline inspection.

“Advances in inspection technologies, especially those related to inline inspection, have advanced our ability to predict future performance in ways that even 20 years ago were not considered possible. Assessment methods are advancing, although there remains work to be done related to uncertainties in material performance and the need for improved predictive analytical models.”

Then there is his specialty: composites.

“Finally, in terms of rehabilitation, advances in composite repair material have been significant, based on investments by both operators, regulators, and composite repair manufacturers. Through full-scale testing we have demonstrated the capabilities of the repair technologies. Twenty-five years ago, we were content to reinforce corrosion; today, we are reinforcing dents, branch connections, elbows, planar defects, and even crack-like features.

Though there are several outlying factors responsible for the surge in R&D, Alexander believes it is the essence of the pipeline industry to take seriously its responsibility for operating safe systems.

“One of my favorite aspects in serving the pipeline industry is the willingness that operators have to work and partner together to tackle challenging problems. This is reflected by the significant number of Joint Industry Programs that have been put together, as well as research sponsored by organizations such as the API, GTI (Gas Technology Institute), and PRCI.

“Although the U.S. and Canadian governments have made commitments to helping advance technology through performance-based regulations, most funding comes from operators, technology companies, and investors. This is as it should be. With performance-based regulations, industry is provided with a framework against which to operate. It is our job as an industry to identify the best technologies that ensure regulatory intentions are satisfied.”

Beyond improved inline inspection tools, Alexander expects future R&D will focus on in-the-ditch technologies, especially those related to material verification.

“Lastly, and I’ll admit to some bias, repair technologies are going to continue to advance; this includes both steel-sleeve technologies as well as composite repair systems. Through research and testing we are developing a greater understanding on how these repair technologies work and their ability to permanently restore the serviceability of pipelines having defects.”

He acknowledges a lag in data assessment methods and techniques.

“There is always a give-and-take between data generation (i.e., ILI) and data assessment. We can do a better job validating assessment methods via full-scale testing that will lower the risk in leaving certain features and anomalies in service.

“It’s impractical to repair every feature. We need assessment methods that allow us to make the best decisions regarding future operation. Further, through testing we can validate that the more severe features can be repaired by the appropriate repair technologies, whether they be steel or composite,” Alexander concludes.

ENDURO Pipeline Services Inc.

There is no question that Tulsa, Okla. is among the global centers for the inline inspection industry, and ENDURO Pipeline Services is a beehive of activity for this growing business.

Here is why.

“The need for technical solutions to address the needs of the energy industry has never been stronger,” declares ENDURO’s technology director, Grant Coleman.

“As the societal impact of our collective energy use has moved into the forefront of public discourse, there is an increased awareness of the role technology has to keep energy moving safely and cleanly. Technological improvements allow for infrastructure to be operated with a higher safety record and more efficiently than ever before.”

Coleman explains the combination of factors encouraging technological advances. 

“Recent price pressures in the oil and gas sector have made some traditional sources less economically viable and are pushing for innovation to bridge the gap. The energy industry is transitioning into a more visible societal role which has helped drive the goal of zero incidents.”  

He suggests that the many areas of active research in both public and private companies pertaining to the pipeline sector all boil down to one need.

“The key to successful pipeline operation is information—the right information.  The information which is used to manage pipeline assets must be as accurate and complete as possible, free from distraction. Many advances are being made to understand mechanical damage, mechanical properties and defects such as complex corrosion, pinhole sizing, and cracking. This is only part of the solution. 

“Effective means to manage and mine the wealth of information is key. Machine learning or artificial intelligence techniques are in their relative infancy but offer a tremendous opportunity to better leverage the information from historical, current, and future technologies applied to the industry,” he said. 

As for customers, they mention the need for increased utilization of multiple technology tools, reducing disruptions to daily pipeline operations, coupled with continuous improvements of POD, POI performance of all ILI technologies.

“In order to drive improvements and complete the feedback loop, there is a push to increase the proficiency of field technicians across all nondestructive technologies. To make the best and most timely use of information, customers want to accelerate actionable data reporting times while maintaining the accuracy of the results,” Coleman said. 

Pipe Spring LLC

Shawn Laughlin has traveled the world helping operators repair damaged pipelines. The former president and CEO of Clock Spring Company Inc., Laughlin launched his own company, Pipe Spring, in 2018. Unlike others interviewed, he suggests that the demand for R&D is not much different than in past years.

“Over recent decades, the improvements in various technologies have given the pipeline sector the technical ability to produce better and more consistent quality pipe, better coating, better integrity products, faster fabrication methods, and better inspection methods. 

“Today’s prime driver is not, ‘how can we do it better, faster or for less money,’ it is rather ‘how can we obtain all of the various jurisdictional approvals, maintain our social license to operate, and actually get it built.’ For new projects, the social and political issues have ascended. However, for existing lines and integrity efforts, the industry has a healthy R&D attitude to mitigate threats and maximize integrity. Controlling costs is always part of the equation,” Laughlin explains.

Stricter regulations have played a useful role as well.

“The potential of stricter regulation, whether operational or environmental, focus R&D efforts. In many cases, these efforts produce useful advances that lead to cost-effective methods and technologies. The regulators have done a good job of communicating the direction and the industry has listened.”

He said the midstream pipeline sector has been the beneficiary of many applied technologies for which the real research was done outside of the industry.

“The development part of this outside R&D is done to a very large degree by industry. Government may have made the research investment for military, defense applications, or aerospace application while the development is done within industry for the pipeline sector.”  

Where does he see future R&D leaning?

“Nondestructive examination methods for pipelines will continue to improve via various advances in both inline inspection and external inspection. As pipeline integrity threats are better identified, categorized, and sized, the need to mitigate these threats will grow. ERW (electric resistance welded) seams, cracks of various origin and type, design factor changes, and other stress-dependent concerns will require new advances in technology.

“These will require significant axial strength, fracture toughness, essentially immediate sharing of load, and modulus very near that of traditional pipe steel grades. In addition, the repair or mitigation itself will need to have fracture toughness properties and intrinsic mitigation of integrity threats caused by external damage,” he says. 

For new construction projects, steelmaking and pipe fabrication technologies will focus on cost-containment.

“This is likely to result in a continued move toward very lean chemistry steel. The grain structure will be controlled via aggressively controlled cooling rates and rolling methods. New products, services, methods, or procedures will be required for field fabrication and welding. Strain-dependent consideration will become a greater focus.  

Clock Spring Company Inc.

Buddy Powers, vice president of product management and technical services for Clock Spring, the Houston-based leader in composite repairs, says 21st Century technologies are rapidly securing a lofty place in the pipeline business.

“There is a strong push to work from platforms that many industries are advancing—such as artificial intelligence and data analytics—to help monitor risk and establish asset life expectancy. The industry will begin to leverage new manufacturing technologies such as nano additives and 3-D printing.

“Three decades ago, in a move away from hot work and asbestos coatings, the industry saw the introduction of high-performance plastics and composites. We developed better solutions, and continuing improvements in composite technology are introducing more options.”

Regulators insist that technology advancements provide a level of safety beyond standard process control, he finds.

“For example, repair codes provide tables for acceptable repairs to specific defects in line pipe. An operator wanting to deviate from the repair table must show a valid engineering reason for using an alternative, like a composite, on a lamination or linear indication. Advancement and validation of technologies allow operators a safe, effective way to push R&D results.”

Upcoming regulatory changes for horizontal directional drilling are another example.

“They will require installation solutions that protect the line as it is being installed. Composites have a leading role to play here, and field applications have proven their viability.”

Powers agrees with others interviewed who feel that advances in data management and analytics will have the greatest impact on the midstream sector. The ability to predict integrity threats and run virtual integrity management processes will have an enormous impact on safety and asset integrity.

“The most prominent need is for on-demand service. Stakeholders want service and delivery at ‘Amazon’ speed, which means providers will need to deliver engineering assessments and repairs much more rapidly going forward. Being able to deliver proven, reliable products that can be kept in inventory on site will go some distance toward meeting this expectation,” Powers concluded.